Decorative article and method of making same



y 1945- I A. ROSENTHALJ 2,377,042

DECORATIVE ARTICLE AND METHODOF MAKING SAME Filed Sept. 9, 1944 2SheetsSheet l I 4 HVLLFIN Russ/v THFIb INVENTOR 1 7L945.

wam/x! ATTORNEY y 1945- A. ROsENTHAL I 2,377,042

DECORATIVEARTICLE AND METHOD OF MAKING SAME Filed Sept 9, 1944 2Sheets-Sheet 2 Hm, H N' Russ/v THHL ll qnll- INYENTOR ATTORNEY PatentedMay 29, 1945 UNITED STATES PATENT OFFICE DECORATIVE ARTICLE :AND METHODoF MAKING SAME Allan Rosenthal, Brooklyn, N. Y.

Application September 9, 1944, Serial No. 553,325

Claims.

This invention relates generally to decorative materials and moreparticularly to a novel and useful decorative article composed ofthermoplastic material and methods for making the same.

In the decorative arts there has been a great increase in the use ofthermoplastic materials which are formed under heat into variousdecora'ted useful articles, Such articles have had a wide use and sale,particularly when the material of which they were composed was of atransparent nature so that the light reflecting and refractingcharacteristics thereof were taken advantage of.

Rod-like or tubular forms have presented prob- Items in the large scale,low cost production thereof because of the large amount of hand-toolingand hand-polishing required, This difficulty is particularly apparent infaceted structures where the individual facets or reflecting surfacesrequired individual polishing or burnishing to produce the desired lightreflecting or refracting characteristics. Another disadvantage flowingfrom the use of pre-formed rods or tubing and then decorating the samebyadditional surface incising or abrading treatment, lies in theconsiderable amount of machining necessary to produce the rod or tubeforms or the considerable expense of the provision of a plurality ofdifferently sized extrusion dies. Furthermore, if the material soformed-is to be readily adapted formeeting various problems ofdecoration or the fabrication of a multiplicity of articles,considerable inventories of the various tube or rod diameters must'bemaintained in stock.

Such disadvantages have been overcome in the present invention by thefact that the effective external diameter of the finished product may bequickly and easily varied by adjustments in the widthrand thickness inthe blank from which the decorative articles are formed.

It is, therefore,among the principal objects of the present invention toprovide novel and useful decorative objects and material and a methodfor producing the same which produces a superior article from adecorative standpoint and one which is more durable and which-may beproduced in relatively large quantities at low cost.

Another object of the present invention lies in the production ofarticles of the class described undesirable visibility of said conductoris sub stantially reducedand may in fact, be' turned into an enhancementof the product.

These objectsand other incidental ends and ad vantages willmore fullyappearin theprogress of thisadisclosure and be pointed out in theappended claims.

In the drawings, similar reference characters designate correspondingparts throughout the several views of eachembodiment.

Figure l is a fragmentary view in perspective of a blank strip ofmaterial in the first stage of its fabrication in accordance with thepresent invention.

Figure'Z' is a fragmentary view in perspective showing the blank stripof Figure 1 during the second 'step o'f rthe herein'disclosed method.

Figure '3 is a front elevational view showing the blank stripon-areduced scale during a third stage in the present method ofmanufacture with as sociated apparatus therefor. 1

Figure 4 is a vertical sectional view of Figure 3 asseenfrom thepliane-l-l thereon.

1Figure5 isa iragmentary-elevational viewof a decorative :article, aproduct of the herein described method.

Figure fi is a fragmentary view in perspective of the decorativearticleshown in Figure 5. I

Figure-f7 is a fragmentary view in perspective of a blank strip ofmaterial in the first stage'of its fabrication in'accordance with asecond embodi ment of the invention. ,7 I

Figure 8 is a fragmentary view in perspective showing the blank strip ofFigure 7 during the second stepof the method of the second embodiment ofthe invention.

Figure 9 is ...a fragmentary view in perspective of the decorativearticle, a product of the method in the v second :embodiment of theinvention.

Figure 10 :is a fragmentary view in perspective of ablankstripofmaterial-aswell as the secondary strip and conductor in athirdembodiment of theinvention.

Figure 11 is a perspective view, fragmented, showing the stepfollowingFigure l0 Figure 'IZ is afragmentary perspective view of thethird-embodiment of the-invention.

Turning now to the first embodiment of the invention illustrated inFigures 1 to '6 inclusive, the decorative article enerally indicated byreference character :10 is preferably formed from a single blank orstripl1 composed of thermoplastic material. For the purpose of avoidingunnecessary repetition in connection :with this disclosure, thespecification .may :mention the thermoplastic m-aterial, methyl-methacrylate, sold under trade-marks such as "Lucite or Plexiglass, butit will be understood by those schooled in the art to which the presentinvention relates, that other thermoplastic materials may be used.Furthermore, such thermoplastic materials may be transparent,translucent or opaque and they may be homogeneous or may consist ofincomplete mixtures of a plurality of different kinds of thermoplasticmaterials. As will more fully appear in the progress of this disclosure,the ornamental effect of the decorative article III is enhanced when theblank II is composed of a transparent or translucent material since thelight reflcting and refracting properties of the thermoplastic materialunder such circumstances, is taken advantage of.

Turning to Figure 1, the blank II may be of any suitable size, dependingupon the dimensions which it is desired that the finished product Ishall have. The blank II may either be a prefabricated strip of the sizeand shape shown or the same may be cut from a larger piece of the rawmaterial. Where, for example, the base material of which the blank IIIis composed, is a cast synthetic resin, the blank or strip II may besevered from a larger cast slab.

As contrasted With prior art methods of handworking, irregular plasticshapes in which the configuration of the article is altered by machiningand polishing when in an almost unfinished state, in the present methodthe blank II is given whatever surface decoration it is desired to giveit, while the blank is in a flat and regular shape. Thus, the topsurface I2, the bottom surface I3, and side edge surfaces I4 and I5 mayat this time receive any desired decorative treatment. Such treatment.for example, would include buffing to a high polish; frosting producedby using abrasives of varying degrees of fineness;

fuming by the use of volatile materials adapted to affect the surface ofthe particular material of which the blank I I is composed; full orpartial lacquering or coating, producing predetermined surfaceirregularities by suitable rolling or stationary dies with heat andpressure, and the like. In the fabrication of the article I0, it isdesirable, however, that such surface treatments as have been impartedto the blank II, be not of such high degree as to destroy the generalconfiguration thereof so as to lose the general helical, fluted effectin the article III.

Next, the blank H is subjected to the action of heat. This may be donein a suitable oven. Such an oven is shown in Figure 3 in which the ovenbody I5 may be composed of suitable insulating material and may beprovided with a viewing opening I1, the latter in turn being closed by atransparent plate. The oven I6 may have suitable end walls I9 and 20,provided with orifices 2| and 22 which act as bearings for the axle rods23 and 24. The body I6 may be provided with a door 25 for the insertionor removal of the material being treated. Heat to the oven may besupplied by air passing upwardly through the conduit 26 and upwardlthrough the openings 21, over the blank II and out through the fiues 28.The air within the conduit 26 may be heated in any suitable manner, asfor example by the gas flames 29.

After the blank II has been subjected to the action of the heated airjust described, a length of time sufficient to cause it to reach atemperature of fusion, the blank I I is folded transversely about animaginary longitudinal line bisecting the top surface I2. This fold ispreferably not a complete fold so that the corner edges 30 and 3I toucheach other along the line 34 (see Figure 2) while the corner edges 32and 33 are relatively widely spaced. This incomplete folding spaces theopposed folded portions of the top surface I2 so that it then forms thecurved inner wall 35. Similarly, the bottom surface I3 forms the curvedouter wall 36.

With the blank I2 in the stage shown in Figure 2, the action of the heatthereon is continued so that it may remain in a plastic state and theends 31 and 38 are grasped within suitable chucks therefor, said chucksbeing indicated by reference characters 39 and 49 (see Figure 3). Thechucks 39 and 40 are secured to the rods 23 and 24, respectively, andsaid rods at the extremities thereof, are provided with the rotatingmeans H and 42. The rotating means H and 42, in the case of manualoperation of the process, may be ordinary handwheels. Where desired,however, the wheels may be power driven in any suitable manner.

With the soft blank II in the form shown in Figure 2 indicated by thechucks 39 and 49, the chucks 39 and 40 are rotated in oppositedirections aboutan axis penetrating the rods 23 and 24 and at the sametime, the chucks 39 and 40 are moved outwardly away from each other.Obviously, assuming that the heat, and therefore the plasticity of themass between the chucks 39 and 40 may be maintained uniformly, acorresponding effect will be obtained by the rotation of only one of thechucks 39 or 40 and the move- 7 ment of only one of said chucks awayfrom the other.

As a result of the tortion and stretching steps just described, the sideedges I4 and I5 take on a helical spatial arrangement, so that the massafter the twisting and pulling, appears as shown in Figures 5 and 6.Obviously, the relativ average diameter of the article III will beaffected by the degree of stretching to which the plastic mass issubjected and the greater the pull, the finer it becomes drawn. Thedegree of pulling or elongation of the mass in its plastic state willalso affect the pitch of the primary flute generally indicated byreference character 4|, which is formed by the side edges I4 and I5 asnow distorted. The number of complete rotations of one of the ends 31 or38 with respect to the other, will also affect pitch and configurationof the flute 4|.

By virtue of the action of the material under the processed stepsdescribed, the corner edges 32 and 33 stand up sharply and secondaryfurrows 42 and 43 are formed outwardly thereof. The furrows 42 and 43border a helical bulge 44.

When the decorative article ID has assumed the desired shape, the heatis removed, for example by stopping the flow of air over the plasticmass and the mass is permitted to congeal. After suflicient cooling, therod like decorative article I0 is complete and may be cut inpredetermined lengths to suit subsequent manufacturing steps in whichthe article is used. It is important to note at this point, that afterthe plastic masshas hardened, no additional polishing or buffing isrequired. This is so because only suiiicient heat has been utilizedduring the forming step to permit the stretching and twisting operation.Not enough heat has been used to create a substantial change in therelatively exposed surfaces of the article I0. It may be further notedat this point, that since the curved inner wall 35 is more or lesscylindrical in general configuration, the opposed walls thereof do notcontact each other. Thus, the curved inner wall 35 forms an elongatedchannel or chamber indicated generally by reference character 45 whichmay be filled with a material having a different refractive index thanthat of which the blank H is composed. Such materials include water,air, or another plastic material. Such volume of material which is of adifferent refractive index than the blank i I, causes additional bendingof light rays, adding to the brilliance and attractiveness of thefinished article -10.

Turning now to the second embodiment of the invention illustratedinFigures '7 and 9 inclusive, for the purpose of avoiding unnecessaryrepetition, parts corresponding to those of the first embodiment aregiven the same reference char acters with the addition of the prefix 1.

The second embodiment differs from the first embodiment principally inthe addition of the secondary blank elements I50 and I51. These maybe ofa different material or haveadifferent color from'the main body'blank Il I. Thus, when these secondary blank elements are stretched and twistedalong with the body blank Hi, the opposed angular surfaces H4 and H5 ofthe primary flute I will present different appearances with aninteresting decorative effect. The step of placing the secondary blankelements along the outer longitudinal edges of the blank Hi, isperformed prior to the trans verse folding along a longitudinal line onthe upper surface of the blank HI. From this point forward the othersteps described in detail, in connect-ion with the first embodiment, arefollowed.

Turning now to the third embodiment of the invention illustrated inFigures to 12 'inclu sive, here again for the purpose of avoidingneedlessrepetition, parts corresponding to'those of the first embodimentare given the same reference characters with the addition of the Thethird embodiment of the invention differs from the first embodimentprincipally inthe filling of the chamber or channel 45 of the firstembodiment, with an electrical conductor, preferably disposed within atransparent or translucent tube of thermoplastic material 50. Since mostof thie thermoplastic materials {suitable for use in connection with thepresent invention have a relatively highdielectric capacity, thedisposition of an electrical conductor within the decorative article 2!permits the same to be used as a support for illuminating devices andother devices must be conducted. By virtue of the refracting andreflecting effect of the twisted and stretched plastic material formingthe blank 2 ll, the image as viewed by the user of the plastic material245, is considerably distorted and broken up so that it does notnormally present a continuous rectilinear image but rather a series ofbroken and twisted colored areas. Thus, decorative articles such as thedecorative article 2H1, may form the hanger portions or bases of lampsand the functional aspects of the electrical conductors transmittingenergy to the light giving portions of the lamp are reduced to aminimum. While in the drawing only a single conductor is shown asdisposed within the plastic 245, obviously a plural number of conductorsin spaced relationship may be used. This may be accomplished by theincorporation of a plurality of conductors in individual plastic tubesor wrappings in juxtaposed relation. In the fabrication ",Of the "thirdembodiment of the invention the central gplastic portion @or theconductor may be inserted into the channel or chamber 45 of thedecorative article 10 or the conductor .246 may-be of an elastic natureand may be installed prior to the folding operation which inturnzpretcedes the stretching and twisting. I-Such resiliency of theconductor :246-may be obtained :in :any suitable manner as for ex ample'by helically coiling the conductor. It maythus beseen that 21 havedisclosed a novel and useful decorative article and methods of makingthe same wherein such articles may be produced in large quantitiesat'relatively low cost. The finished'article presents a highly desirable appearance and has many utilitarian aspects outlinedhereinabove.

Iwish it to be understood that I do not-desire to be limited to theexact details of construction shownand described, for obviousmodifications will occur toa personskilled in .the art.

:I claim:

1. As anew article of manufacture, a decorative article comprising: anelongated tube of transparent materialhaving ahelically fluted exteriorand havinga .hollow internal channel of substantially ellipticalcross-section.

2. A decorative article comprising: an elongated tube of lighttransmitting material having a hollow internal .channelofsubstantially'elliptical cross-section, oneend of said ellipse forminganacute angle-and having a helicalfiute extending 'along the outersurfaceof said tube.

3. As a newrarticleof manufacture, a decorative article comprising: anelongated tube of light transmitting material (having a hollow in temalchannel .of substantially elliptical cross section; a helical fluteextending along the outer surface of-said tube; and secondary furrowshelically extendingalong said-tube in spaced and parallel relation tosaid flute.

'4. As anew article of manufacture, a decorative article comprising: anelongated tube of light transmitting material having a hollow internalchannel of substantially elliptical crosssection; a helicalfluteextending along the outer surface of said tube; secondary furrowshelically extendingalong said tube in spaced and parallel relationto'said flute; :and:a helical'bulge disposed substantially midwaybetweenadjacent convolutions of saidflute.

5. As a new article of manufacturea decorative article comprising: .anelongated tube of light transmitting thermoplastic material having ahollow internal channel of substantially elliptical cross-section and ahelical flute extending along the outer surface of said tube, said flutebeing formed by the angular juxtaposed side edges of an elongated blockshaped blank folded longitudinally upon itself and twisted about itslongitudinal axis.

6. As a new article of manufacture, a decorative article comprising: anelongated tube of gated block shaped blank of plastic material, saidblank being incompletely folded about a longitudinally arranged line onthe upper surface of said blank, sufficiently to bring the upperlongitudinal corner edges into contact; said blank being twisted aboutthe longitudinal axis of said article and stretched therealong.

8. A decorative article comprising: an elongated block shaped blank ofplastic material in the form of a tube; said blank being incompletelyfolded about a longitudinally arranged line on the upper surface of saidblank, sufliciently to bring the upper longitudinal corner edges intocontact; said blank being twisted about the longitudinal axis of saidarticle whereby the longitudinal side edges of said blank form a helicalflute, the exposed surfaces of said flute being composed of materialhaving different light transmitting properties than the material ofwhich the tube is composed.

9. As a new article of manufacture, a decorative article comprising: anelongated tube of light transmitting material having a, hollow internalchannel and a helical flute extending along the outer surface of saidtube; and a core portion of material differing in light handlingproperties from the material of which the tube is composed, said coreportion being disposed within said channel.

10. As a new article of manufacture, a decorative article comprising: anelongated tube of transparent thermoplastic material having a hollowinternal channel of substantially elliptical cross-section; a helicalflute extending along the outer surface of said tube, said flute beingformed by the angularly juxtaposed side edges of an elongated blockshaped blank; secondary furrows helically extending along said tube inspaced and parallel relation to said flute; a helical bulge disposedsubstantially midway between adjacent convolutions of said flute; and anelectrical conductor disposed within said channel; whereby lightreflected from said conductor through said tube, is refracted so as tocreate a discontinuous visual appearance of said conductor when viewedlaterally through said tube.

11. The method of manufacturing a decorative article including the stepsof: taking an elongated block shaped blank of plastic material, saidblank having ends, a top surface, a bottom surface, a pair of sideedges, and opposed pair of upper and lower corner edges; softening saidblank; and folding said blank transversely about a longitudinal line onthe upper surface of the blank, while the blank is in a plastic state,until the upper corner edges are in contact, to form a tube.

12. The method of manufacturing a decorative article including the stepsof: taking an elongated block shaped blank of plastic material, saidblank having ends, at top surface, a bottom surface, a pair of sideedges, and opposed pairs of upper and lower corner edges; softening saidblank; folding said blank transversely about a longitudinal line on theupper surface of the blank, while the blank is in a plastic state, untilthe upper corner edges are in contact, to form a tube; and twisting saidtube about its longitudinal axis.

13. The method of manufacturing a decorative article including the stepsof: taking an elongated block shaped blank of plastic material, saidblank having ends, a top surface, a bottom surface, a pair of sideedges, and opposed pairs of upper and lower corner edges; softening saidblank; folding said blank transversely about a longitudinal line on theupper surface of the blank, while the blank is in a plastic state, untilthe upper corner edges are in contact, to form a tube; and stretchingsaid tube about its longitudinal axis.

14. The method of manufacturing a decorative article including the stepsof: taking an elongated block shaped blank of plastic material, saidblank having ends, a top surface, a bottom surface, a pair of sideedges, and opposed pairs of upper and lower corner edges; softening saidblank; folding said blank transversely about a longitudinal line on theupper surface of the blank, while the blank i in a plastic state, untilthe upper corner edges are in contact, to form a tube; andsimultaneously twisting and stretching said tube respectively about andalong its longitudinal axis.

15. The method of manufacturing a decorative article including the stepsof taking an elongated block shaped blank of material which may besoftened, said blank having ends, a top surface, a bottom surface, apair of side edges and opposed pairs of upper and lower comer edges;placing an independent strip of material, which may be softened, on theupper surface of the blank; softening said blank and independent strip;folding said blank transversely about said independent strip until theupper corner edges of said blank are in contact to form a tube enclosingsaid independent strip and simultaneously twisting; and stretching saidtube respectively about and along its longitudinal axis.

ALLAN ROSENTHAL.

